Method and systems for converting shipping pallets to components for shelter and green infrastructure

ABSTRACT

A method of converting a shipping pallet for use as a building component for a environmentally green super-structure and green infrastructure including a range of building types from tent structures to homes medical facilities, classrooms, small commercial, and small industry. In one example, a hinged pallet frame is attached to an existing pallet to form a construction panel, and multiple panels are assembled and pivoted to form structures. A kit for converting a pallet comprises tubular frame elements, hinge connector elements, and leg frame elements. In other examples, new pallet-like panels are created with foam core, stress skin, and protective frames that facilitate interconnection.

RELATED APPLICATIONS

This is a continuation-in-part application of U.S. patent applicationSer. No. 16/224,326 filed by applicant on Dec. 10, 2018, which claimspriority from U.S. Provisional Patent Application No. 62/607,232 filedby applicant on Dec. 18, 2017.

BACKGROUND Field of Invention

The current invention relates to the use of pallet modules and palletframes to serve as improved pallets and as construction modules.

SUMMARY

This application describes a redesigned and engineered shipping palletused in a manner that enables components to serve either as an entirelynew shipping pallet or enables use as building components for aenvironmentally green super-structure and green infrastructure includinga range of building types from tent structures to homes medicalfacilities, classrooms, small commercial, and small industry.Decentralized infrastructure needs including methods of mounting orprotecting PV's, towers for wind systems, housing for biomassgasification, battery banks, and provisions for water harvesting, wastewater treatment, organic waste treatment, porous paving and bankstabilization. Food is addressed in the form of greenhouses, and animalshelters as well as fish in the form of aquaculture, raised bed gardens,and organic waste to food.

The uniqueness of the approach is its ability to piggyback onto a largeinternational manufacturing, shipping/distribution and inventory systemwith significant spatial correlation to a wide range of clients fromecotourism, to the military, to disaster and other needs worldwide. As aBlue economy product it offers the pallet industries a new andsignificant clientele never considered in the form of disaster reliefmitigation and prevention, humanitarian issues of immigrationhomelessness, environmental and war refugees and the DIY industryincluding tiny houses grow homes, camps, retreat centers; many of thesebeing served by custom non modular, non pre-manufactured interoperablecomponents. Together these and other clients that require user andenvironmentally friendly building along with accompanying employmentopportunities at all levels of the development process is the backgroundand purpose of this patent application. The sPOD pallet designedpurposely to be repurposed can address disaster relief shipping depotsand harbors, water pollution, food deserts and shortage, lack ofsanitation, shelter, as well as other use configurations that developthrough a crowd sourcing approach that enables feedback and furtherevolution in the use of the system and to use human capacity to support,independence, cooperation, resilience and creativity.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is top perspective view of an example pallet.

FIG. 2 is a top perspective exploded view of components of examplepallets.

FIG. 3A is a top perspective view of a conventional wood palletretrofitted with a frame.

FIG. 3B is a top perspective view of a plastic pallet retrofitted with aframe.

FIG. 3C is a top perspective view of a heavy duty pallet retrofittedwith a frame.

FIG. 3D is a side perspective view of a protective pallet frame section.

FIG. 3E is a cross section view of the protective pallet frame sectionshowing the storage of various items.

FIG. 3F is a side perspective view of a fabric roll being inserted intoa protective pallet frame section.

FIG. 3G shows various materials that may be stored in a frame element.

FIG. 4A is an exploded top perspective view of a protective frame andand hinged leg frames.

FIG. 4B is a top perspective view of a pallet with a stressed skin.

FIGS. 5A-5E show example pallet types.

FIG. 5A shows a medium duty pallet,

FIG. 5B shows a pallet.

FIG. 5C shows a heavy duty pallet.

FIG. 5D shows a box pallet and extended pallet.

FIG. 5E shows a mobile pallet.

FIG. 6A is a top perspective view of a spillage confinement frame.

FIG. 6B is a top perspective view of a light duty pallet.

FIG. 6C is a top perspective view of a retrofit kit for making existingpallets modular.

FIG. 6D is a top perspective view of a medium duty pallet.

FIG. 6E is a top perspective view of a self propelled pallet.

FIG. 6F is a top perspective view of a drum pallet.

FIG. 6G is a top perspective view of a container box pallet.

FIG. 6H is a top perspective view of an extended pallet.

FIG. 7A is a top perspective view of a raised bed frame.

FIG. 7C is a top perspective view of a lounge chair base with hingedback.

FIG. 7B is a top perspective view of stools and a table.

FIG. 7D is a top perspective view of a work station desk.

FIG. 7E is a top perspective view of an example partition.

FIG. 7F is a top perspective view of an open frames combined withcowling insert.

FIG. 7G is a top perspective view of an example shed.

FIG. 7H is a top perspective view of an example cover.

FIG. 7I is a top perspective view of an example carport.

FIG. 7J is a top perspective view of leg cowlings used as packaging forcowlings of or parts.

FIG. 7K is a top perspective view of of leg cowlings laid flat forcompartmentalized packaging.

FIG. 8A is a side perspective view comparison of a prior art SIP paneland sPOD components.

FIG. 8B is a side perspective view of example fast deployment fold outpanel tents.

FIG. 8C is a side view of the example tents of FIG. 8B.

FIG. 8D is a side perspective view of examples very low cost shelters.

FIG. 8E is a side perspective view of example door frames and windowframe.

FIG. 8F shows perspective view and side views of example hollow coreutility walls and concrete poured or sand-filled walls.

FIG. 8G is a side view of 12 volt wiring embedded within a stressed skinpanel.

FIG. 8H are top perspective views of a plurality of panels folded tostructures.

FIG. 8I are top views of example floor plans which can be created byvarious combinations of single panels and sets of panels.

FIG. 9A shows top perspective views of example porous paving and bankstabilization.

FIG. 9B shows side perspective views of an example living wall andliving roof.

FIG. 9C shows top perspective views of example Community IntegratedDistrict Utility Spines.

FIG. 9D shows top perspective views of example green machines.

FIG. 10 shows an example manufacturing process for carbonized foam.

FIG. 11 is a side perspective view of an sPOD branding symbol.

FIG. 12 is a front perspective view of a tubular frame set.

FIG. 13 is a front perspective view of an example square tubular frameand an example round tubular frame.

FIG. 14A is a front view of an example square tubular frame holding anunfolded hinge connector and hinge pins.

FIG. 14B is a top view of the unfolded hinge connector of FIG. 14A.

FIG. 14C is a top perspective view of the hinge connector of FIG. 14A ina folded orientation.

FIG. 15A is a front view of square tubular frame holding retrofitbrackets, pins, and bolts.

FIG. 15B is a top perspective view of a retrofit bracket of FIG. 15A.

FIG. 16A is a front view of square tubular frame holding leg frames.

FIG. 16B is a side view of an unfolded leg frame.

FIG. 16C is a side view of a folded leg frame.

FIG. 17A is a front view of square tubular frame holding strut rods.

FIG. 17B is a top view of strut grid.

FIG. 17C is a cross section detail showing strut grid formed with rodsoriented in the X-direction

and the Y-direction.

FIG. 17D is a top view of a strut rod with a T-sleeve and an elbowsleeve.

FIG. 18A is a front view of square tubular frame holding stress skinhinge plates.

FIG. 18B is a top view of a stressed skin positioned over a foam core.

FIG. 19A is a front view of square tubular frame holding fiberreinforced abrasion protection strips.

FIG. 19B is a top view of applied fiber reinforced abrasion protectionstrips.

FIG. 20A is a cross section of a foam core construction panel fabricatedfrom kit components.

FIG. 20B is an example foam core construction panel of FIG. 20A with legframes.

FIG. 21A is an example retrofit pallet.

FIG. 21B is another example retrofit container pallet.

FIG. 22A is a side view of a portion of a stacked pin panel.

FIG. 22B is a side view showing an unfolding sequence of a stacked pinpanel.

FIG. 22C is a top view of a multiple fold pinned panel.

FIG. 22D is a side perspective view of a panel box formed on a pallet.

DESCRIPTION sPOD Green Superstructure and Infrastructure Diagrams

There are four main conditions for a super structure (foundation—6attributes, wall—4 attributes, floor—6 attributes, roof—4 attributes);and three main conditions for infrastructure (Energy—7 attributes,Water—8 attributes, Food—6 attributes).

Basic Components

In this specification the term tubular means a hollow elongated member.In some examples the cross-section may be a rectangular or circular.FIG. 13 is a front perspective view of an example square tubular frame220 and an example round tubular frame 221.

In some examples, the frame member may not be tubular, and may beprovided as an an elongated flat plate.

Basic components-comprise six separate elements and three retrofits toexisting pallet applications making a total of nine conditions thatrequire explanation:

FIG. 1 is top perspective view of an example pallet 100 with a hingedpallet frame 200 and legs 280. In this example, the hinged pallet framefunctions as a protector/holder and structural frame for a stressed skinpanel and comprises 7 inner features that key into and hold in place thestressed skin panel. This frame also has the necessary slots and holesfor holding the struts and hinge pins in place all having a wide varietyof other applications. The frame can be released from the panel simplyby removing any of the corner hinge pins and can therefore be used alsofor other purposes when incorporated within the series of pallet typesor the home interior and yard, superstructure and infrastructure needs.Structural applications include (including the creation of box columnsbeams and space frame members. Another attribute of the frame is thefact that it has a series of alternating hinge sleeves top and bottomaround the perimeter that are used in various applications from holdinglegs in place on the bottom of the pallet or as spacers. The legs arealso manufactured to be the same leg dimensions and characteristicshinge holes with the struts and hinge pins described below enableconnectivity of frame to frame in planner or a perpendicular fashion. Anextension connected to the pallet protuberances mentioned earlierenables the frame to also be retrofitted onto existing wood plastic orpharmaceutical pallets so that they can all become modular buildingcomponents with the same outside dimension once they have an insulationpanel placed within the retrofitted frame. In one example, an insulationpanel is created by attaching a bladder or stress skin over a foam core,such as a carbonized foam core.

The frame and skin structure facilitates efficient expansion andreconfiguration of structures and the disassembly and reconfiguration ofthe components.

FIG. 2 is a top perspective exploded view of components of examplepallets. A bladder assembly 309 comprises a belly protector 310 and atop cover 320. Hinges 281 are provided for the pallet legs. Caps 284 areprovided for leg areas.

Connector Block Hinge Features

A connector block typically has spaced apart hinge pin sleeves that areconfigured to mate with offset hinge pin sleeves provided on a secondconnector block.

Connector blocks are typically provided on each end of the frameelement, and one or more intermediate connector block as providedbetween the corner blocks. The use of multiple connector blocks promotestronger hinging and pivoting of construction panels.

A bladder surface protection skin 320 is attachable using snap-on sides310 that go over the pin of hinge pin on the frame. The pallet isprepped to have leg hole areas removed or remain as an entire plane.When the perforated areas are popped out for the legs, the bladderbecomes a protective belly under the pallet panel for purposes ofavoiding puncture by the fork lift and for protection of the strut grid.This bladder attribute is used for many other purposes such as quickthin uninsulated field structures and sheds held together with itemslike long ¼ inch rebar.

Bladders are protective cover coverings for the top or bottom surfacesof a retrofitted panel. In one example, a bladder is a fiber reinforcedabrasion resistance surface lot applied over a pallet or a foam core toprotect the pallets from forklifts underneath, or to protect the pallettop from abrasive loading.

A grating or strut grid 430 supports pallet legs. In one example, strutsin the strut grid and pins comprise approximately ¼ diameter biobasedfiber reinforced material the longer struts containing slight bumps onall surfaces to function as thin reinforcing bars for other purposes,the struts being 4 foot pins are counter sunk into the stressed skinpanel one more in depth than the other so as to be able to orthogonallycross each other as described below. Since they crisscross each otherthe counter sink must accommodate ½ inch depth-2 times the ¼ inch strut.There are two types of Pins both made of the same material and diameteras the struts one shorter and straight but the other although of thesame diameter is U-shaped for connecting the hinge areas of the frame invarying angles U shaped pins can be stored within one or more the legcowlings when the leg cowling is not also filled with the stressed skin.Again the U-shaped pin enables a face to face connection or stacked oneframe to the frame above when needed.

Leg Frames and Legs

Leg frames typically have the same height as frame elements. A hardfiber reinforced epoxy may be used for the leg frame.

Legs may be added to custom pallets, or may serve as spacers betweenpallets so that concrete or insulated material may be added between thepallets.

Hinged leg frames 283 are similar to the large frame and are of the same3″ depth but with approximately 6″×6″ or a 8 inch by 8 inch footprint.These cowlings also have their protruding key on each side to hold asmaller stressed skin leg in position. They also have a hinge on allfour corners for removal form stressed skin leg as well as hinge holeson the top and bottom edges just like the large frame so they can alsobe stacked with the U-Pin or laid out flat. These legs can be connectedin plan or stacked or in orthogonal orientation just like the main frameusing the struts.

Examples 330 and 340 show alternative stress skin panels. Stressed skinpanel 330 has corners and side and potentially the middle free areas andthe others all solid. The holes are coordinated to enable the legs to bestored within to be dropped out and pinned when used as a 9 leggedpallet. Or a disassembly version with the nine legs can exist when thecowling holders(the struts and hinges are pinned beneath and the legsnot able to recede within the pallet frame until pins are removed. It isimportant to note that the cowlings and therefore the legs can be placedon either side of the pallet to create a configuration of leg panel legpanel sandwich configuration. This means that each side of any panelversion (holes or solid) have the crevices for the struts on both sideswhether used or not used and whether covered top or bottom with thesolid bladder. It is also worth noting that due to the hinges on allframe corners (large and small) that hinged triangular frames can bemade into triangulated surfaces that have structural integrity betterthan the square orthogonal frames and can be become folded plate(whenstressed skin panels are inserted or just be an open of folded spaceframe type beam.

Stressed skin leg inserts or containers 331 are configured to fit withinthe stress skin panel 340 into the leg protective frames possess and keyindentation for the leg frame to hold it in place but most important itis structural and insulative and while adding to the structural capacityof the structural leg frame in order to take heavy loads when used as apallet.

FIG. 4A is an exploded top perspective view of a protective frame 200and hinged leg frames 283

FIG. 4B is a top perspective view of a pallet with a stressed skin 341.

FIG. 3A is a top perspective view of a conventional wood pallet 272retrofitted with a 4 foot×4 foot frame 200. FIG. 3B is a top perspectiveview of a plastic pallet 274 retrofitted with a frame 200. FIG. 3C is atop perspective view of a heavy duty pallet 276 retrofitted with a frame200. All retrofitted pallets can be used within the system asdimensionally coordinated. The retrofitted frame comprise solid stressedskins panel, with no accommodation for disappearing legs, for insulationand to increase impact. The frames are retrofitted with special anglesthat fit into the protuberances of the frame and are bolted into theexiting pallet frame at a point of structural integrity.

The example components include a protective frame assembly 200 cowlingaddition with frame segment 210 and hinge connector 211. Side extensions270 provide forklift protection. In this example, the protective frameassembly comprise a square tube with male and female hinge sleeves onall four corners that are coordinated with the frame so it can beattached to the main frame using the hinge holes either on one face ofthe pallet or the other or on the side of the pallet frame to create inessence a very robust double frame. These cowlings have seven or moreuses when they are filled with a variety of inserts that roll out andbecome covers protectors, insulators and clear uses such as see throughcovers for merchandise as well as windows when used in building. Theseventh cowing use consists of a set of extended wheels with motors GPSsensors, steering mechanism, batteries all enabling the self movementand delivery of pallets with loads on them.

FIG. 3D is a side perspective view of a protective pallet frame section202.

FIG. 3E is a cross section view of the protective pallet frame section202 showing the storage of various items including foam, water repellant217, cargo net 225, camouflage 216, interior or exterior insulation 212,and a motor 228. FIG. 3F is a side perspective view of a fabric roll 204being inserted into a protective pallet frame section 202. FIG. 3G showsvarious materials that may be stored.

Biobased Materials

In these examples, there are two major applications for all bio-basedfiber reinforced materials in sPOD.

A hard fiber reinforced epoxy is used for the frame guard, the legguards and the struts and hinge pin materials.

A foamed core for the stressed skin panels.

There are two types of applications for bio-based foam 1) as a straightfoam 2) as the basis for a carbonized foam for purpose of having sPODtake extreme heat at it core while retaining insulation and punctureresistance.

These traits can be with either panel type, with holes for disappearinglegs or the other solid panel. The most important part is the capacityof the bio-based foam to be carbonized. This means placed into apyrolysis unit or better into a gasification unit in order to use theescape gas as fuel to operated the system. the special attributes ofcarbonized bio-based foam is multiple (EMF protecting of occupants—highstrength, fire proof, termite proof and floatable or able to be floodedpurposely so the structure can become very heavy to adapt to climaticneeds)

Family of Products

There are four pallet product categories that sPOD is capable of beingadapted to and all of these are simply a reshuffling in the use ordelivered components either appearing separately within an inventorysystem or contained within most any pallet:

FIGS. 5A-5E show example pallet types. In one example a kit is providedfor retrofitting existing pallets into the same modular size, a spillagepallet to contain warehouse spill able items, a light duty pallet madeup mainly of just cowlings and struts, a retrofit pallet kit for(existing wood plastic and foamed core pallets),

FIG. 5A shows a medium duty pallet 601 that adds the stressed skin paneland stressed skin legs.

FIG. 5B shows a pallet 602.

FIG. 5C shows a heavy duty pallet 603 with double stresses skin anddouble stacked frames for 55 gallon drum carrying,

FIG. 5D shows a box pallet and extended pallet 604.

FIG. 5E shows a mobile pallet 605 using the cowlings described earlierto hold wheels and axles

Home and Yard Applications Kit Pallet

General conditions comprising inside and out side applications—insidebeing furniture and spatial partitioning, outside being simple sheds,car ports and PV mounting frames to plant and animal support systemsincluding trellis and raised gardens.

Superstructure General Conditions

In this example, the super structure has several attributes conditionsand/or applications;

-   -   1) sPOD fits a so far unfilled niche in the building industry—it        can be a robust 8×8 (or 6×6) block that is incremental in itself        in size and thickness before it is the block to be used (ie        16×16×6 or 12×12×3 etc). It possesses an inter-connecting shroud        frame with hinge type connections, and is insulating and light        and user friendly unlike concrete CMU which are heavy        un-insulating and need mortar to stay together. When it is the        size of a 4×4 foot panel frame, it is smaller than the usual 4×8        structural insulated panel and therefore more user friendly but        with the same strength.    -   2) tents;    -   3) low cost hexagonal structures;    -   4) window and door configurations;    -   5) hexagonal structures;    -   6) fold out structures with the hinged frames and internal        stressed skin panels for foundation/floors wall and roofs;    -   7) Evolutionary plans where buildings comprise a starter unit        with first pallets or top framed panels of pallets with or        without legs and then configured into various box sizes or box        shaped modules from a 4×4×4 to 8×8×8 to 12×12×12 or 16×16×16        feet. Other dimensions are possible but the integrity of the        system stems from its modular growth possessing a double shear        wall that developed as modules are directly added to each other        between module wall that are duplicated.    -   8) sPOD pallet used as forms for concrete or as open wire and        utility chases; and    -   9) when a series of cowling box tubes are retrofitted they can        add various surfaces membranes

Green Infrastructure Utility Housings General Conditions

Green infrastructure emphasizes the use of natural processes (ieminimizing mechanical) to accomplish basic life support this sPODcategory includes

-   -   the use of plants, aggregates, and soils to absorb water on site        verses piping drainage water to other locations and in the        process to clean air and supply oxygen absorb CO2;    -   the use of horizontal and vertical building surfaces with        planting areas to again absorb water, cool surfaces supply        oxygen absorb CO2; and    -   to provide a safe spine to protect utilities (water lines sewage        lanes electrical and communication between buildings while 1        becoming a pedestrian walkway—all using the sPOD building        component to supply the building block to accomplish this form        foundation to trellis and housing of various renewable utilities        that serve this spine.

Example Pallet Applications

FIG. 6A is a top perspective view of a spillage confinement frame 610

using the frame and bladder alone for the purpose of controlling leakingfrom various containers on to the warehouse

FIG. 6B is a top perspective view of a light duty pallet 601 using onlythe larger pallet frame and the leg frames and struts but not stressesskin panel for bags of fibers and other dry organic matter.

FIG. 6C is a top perspective view of a retrofit kit 278 for makingexisting pallets modular and insulating for enabling any pallet to fitthe dimensional standard of sPOD modularity while becoming strong andinsulating for buildings which most shipping pallets do not have astheir characteristics.

FIG. 6D is a top perspective view of a medium duty pallet 603. Thispallet uses all the stressed skin insert sin all the frames so that anormal medium duty pallet can result—from approximately 1200-2500 poundcapacity.

FIG. 6F is a top perspective view of a 4/55 gal drum heavy duty pallet614. By doubling up on the panel surface (including a double frame forholding the extra panel sPOD is enabled to take on extreme weight suchas 4 55 gallon drums

FIG. 6G is a top perspective view of a container box pallet 613 forflowable materials and fluids, the container pallet takes advantage ofthe hinge able panels that enable the sPOD pallet to become acontainment box including the lid.

Example—Container Pallet Construction

At step 1000, the contents are removed from a tubular frame set.

At step 1010, hinge cowling end pieces are attached to the tubularframes to form a tubular frame.

At step 1020, intermediate cowlings are attached to the tubular frameelements at positions corresponding to attachment points on an existingpallet.

At step 1030, retrofit brackets are used to attach the cowlings to thepallet.

At step 1040, the retrofit brackets are bolted to the pallet.

At step 1050, bottom strut rods are attached to the hinge cowlings.

At step 1060, container sides are secured to the strut rods.

In the alternative, a single stressed skin panel is placed inside thetubular frame, and the stressed skin panel is secured to the frame withstressed skin hinge plates.

In one example, stress skins are thin layer fiber reinforced abrasiveresistant surfaces. Stress skins are typically provided on assembledconstruction panels rather than on retrofitting existing pallets.

FIG. 6H is a top perspective view of an extended pallet 612 an extendedpallet both flat and boxed for other size shipments, this feature can belimited to the pallet itself or enable the user to construct a 4×4×8foot small container type pallet with the advantage of all walls usingthe strength of the hinge even on the side.

FIG. 6E is a top perspective view of a self propelled pallet 611 withthe wheeled GPS motorized steering capable cowlings described earlierthe sPOD pallet can become self propelled and self guided with programedwarehouse and inventory capability. In some cases, this pallet mayeliminate the need for a fork lift since the pallet can takeconsiderable weight when duplicating the robust qualities of the drumpallet.

Example—Retrofitting an Existing Pallet

In this example, a plurality of frame members are delivered as a stackedas shown in FIG. 12. which is a front perspective view of a tubularframe set 219. In this example, the set includes 4 rectangular framemembers 219 a which contains hinge cowling plates and retrofit plates;219 b which contains leg frames; 219 c which contains strut rods and astressed skin hinge plate; and 219 d which contains fiber reinforcedabrasion protection strips. The Frame members service storage for aplurality of rods, connector blocks, leg frames, pins, and othercomponents.

FIG. 14A is a front view of an example square tubular frame 219 aholding an unfolded hinge connectors 219 a (also referred to as a hingecowlings 242) and hinge pins 240. FIG. 14B is a top view of the unfoldedhinge connector 242 of FIG. 14A. FIG. 14C is a top perspective view ofthe hinge connector 242 of FIG. 14A in a folded orientation.

FIG. 15A is a front view of square tubular frame 219 b holding retrofitbrackets 244, pins 241, and bolts 243. FIG. 15B is a top perspectiveview of a retrofit bracket 244 of FIG. 15A.

FIG. 16A is a front view of square tubular frame 219 c holding legframes 283. FIG. 16B is a side view of an unfolded leg frame 283. FIG.16C is a side view of a folded leg frame 283.

FIG. 17A is a front view of square tubular frame 219 d holding strutrods 429. FIG. 17B is a top view of strut grid 430. FIG. 17C is a crosssection detail showing a strut grid formed with rods oriented in theX-direction 429 b and the Y-direction 429 a. FIG. 17D is a top view of astrut rod with a T-sleeve 432 and an elbow sleeve 431. The rods areremoved and assemble to form a strut grid. The strut grid has a lowerlevel spaced apart rods oriented and the X direction, and an upper levelspaced apart rods oriented in the Y direction. The ends of each rod areattached to a connector block such as by friction fit, adhesive, or setscrew.

FIG. 18A is a front view of square tubular frame 219 e holding stressskin hinge plates 245. FIG. 18B is a top view of a stressed skin 330positioned over a foam core 334. The stressed skin has a structural edge333, and hinge plates 245 are mounted to a structural edge.

FIG. 19A is a front view of square tubular frame holding fiberreinforced abrasion protection strips 336. FIG. 19B is a top view ofapplied fiber reinforced abrasion protection strips 336.

FIG. 20A is a cross section of an example foam core construction panel102 fabricated from kit components. In this example, fiber reinforcedstress skin 330 is applied to the top and bottom of a foam core 334. Thetop surface is protected by fiber reinforced abrasion protection strips336. A foldable hinge cowling 242 is attached to a hard core edging 247with a hinge plate 244 and to a rectangular frame element 220. FIG. 20Bis an example foam core construction panel 102 of FIG. 20A with legframes 283.

Leg frames are removed and assembled the form square frames which arethen inserted into selected openings between the X and Y rods. These legframes may serve as spacers when a second pallet is stacked on a firstpallet.

A stress skin having a thickness of approximately ⅛ inch is set over thestrut grid. The stress skin has shallow spaced apart grooves oriented inthe X direction, in deeper spaced apart grooves oriented in the Xdirection so that the stress can may be placed on the strut grid.

The connector blocks are removed and attest to a shipping pallet, andframe members or slid through the connector blocks and pinned to securethe frame members to the connector blocks and pallet.

Attaching the Connector Blocks to a Shipping Pallet

In one example, several connector blocks are bolted to each side edge ofthe shipping pallet. Frame members or then inserted through theconnector blocks and secured do the connector blocks.

In order to achieve a consistent construction panel dimension such as4′×4′, it may be necessary to provide additional spacing between theconnector blocks and pallet so that the final width between frameelements is 4 feet.

In other examples, the connector blocks may be attached to the framemembers before attaching the frame members to the pallet.

FIG. 21A is an example retrofit pallet 103 with a foam core 334 appliedover an existing pallet 90.

FIG. 21B is another example retrofit container pallet. In this example,a container pallet 104 is formed by attaching a plurality of legcontainers 283 over existing pallet 90.

sPOD Home and Yard Retail Kit

This kit caters to the retail market but is comprised of componentssimilar to all other pallets but my have extra or less parts thannormal—in the larger sense this kit is meant to enable people who havelost all their furniture to flood or fire or other disasters to gain anew start with a system that is strong and bacterially robust if suchcircumstances were to re-occur.

Indoor Furniture

A few examples of furniture are shown in FIGS. 7A-7G.

FIG. 7A is a top perspective view of a raised bed frame 702 with aheight of the users choice because the pallet legs are additive.

FIG. 7C is a top perspective view of a lounge chair base 706 with hingedback.

FIG. 7B is a top perspective view of a stool 705 made up of pallet legsattached vertically and horizontally, and a table 704 of varyingheights, lengths and widths, for meetings or dining.

FIG. 7D is a top perspective view of a work station desk 708 with legcowling 6 inch deep shelves using the pallet struts as support frames.

FIG. 7E is a top perspective view of an example partitions 722.

FIG. 7F is a top perspective view of open frames combined with cowlinginserts 724 of varying types including light through see through anddesigner patterns ordered by the roll for use with closets, storageshelves and privacy curtains.

FIG. 7G is a top perspective view of an example shed 742.

FIG. 7H is a top perspective view of an example cover 762.

FIG. 7I is a top perspective view of an example carport 764.

FIG. 7J is a top perspective view of leg cowlings used as packaging forcowlings of or parts.

FIG. 7K is a top perspective view of of leg cowlings laid flat forcompartmentalized packaging.

In various examples, the modules may be used to construct outdoorfurniture, shade structures, PV mounts, trellises, benches and picnictable with integrated seating 5.4 tool sheds, greenhouses, fish ponds,and poultry/animal sheds.

Green machines are procedures that use simple nature based procedures toaccomplish everyday talks like make a cistern to hold water form yourroof or to make a tower for a small wind generator or form a grey waterholding area that treats that water using plants or a poultry fish plantfood system using waste

sPOD Super Structure

FIG. 8A is a side perspective view comparison of a prior art SIP panel80 and CMU block 81 versus a pallet module 340, and a cowling frame 202.

There are ergonomic comparative benefits of SPOD relative toconventional construction elements as to size, weight, insulationcapacity, impact resistance. These features out perform the usualconcrete masonry unity or the SIP panel presently used in construction.

There are several types of conditions which may be interconnected usingthe hinge connectors for 4 ft×4 ft panel and 6 inch×6 inch leg. Somecomponents are filled with stresses skin inserts, and others are notfilled. Some example super structure categories are discussed below.

FIG. 8B is a side perspective view of example

fast deployment fold out panel tents including a quick tent 911 aninsulating tent 912 a raised tent 913, and a robust tent 914 for highwind or cold weather.

FIG. 8B is a side perspective view of examples very low cost shelters920 and 930.

FIG. 8E is a side perspective view of example door frames 972 and windowframes 970 incorporating built in hinges, open and solid panels usingvarieties of added cowlings such as clear for windows. In oneembodiment, the support key for holding the original pallet stressedskin panels and feet are used as the door and window stops fold outstructures

FIG. 8H are top perspective views of a plurality of panels 954 folded tostructures 952 and 956. These structures use the hinge capacity of theframes both legs and panels with their associated built-within hingeframes to be foldable foundation. Floors, walls, and roof—some can beused as concrete or sand-filled forms such as the inter-connectable takea part hollow hinged leg frames when they do not have the stressed skininsert.

FIG. 22A is a side view of a portion of a stacked pin panel 921.

FIG. 22B is a side view showing an unfolding sequence of a stacked pinpanel 921.

FIG. 22C is a top view of a multiple fold pinned panel 922.

FIG. 22D is a side perspective view of a panel box 923 formed on apallet 90.

Evolutionary Plan

The 4 foot module enables growth from a tiny dog house size structure tothe ability of the sPOD pallet panels to create substantial houseplans—the special attribute is that we suggest no hallways but directentrance from module unit to module unit (some modules can becirculation to multiple rooms if necessary) but by building in modularincrements enables the wall of each module to touch the next, therebycreating thicker walls at these wall overlaps. Panels can be added indepth and length to enable robust sheer walls between modules to aid inwind and water pressure. FIG. 8H are top views of example floor plans958E-958G which can be created by various combinations of single panels958A, sets of 4 panels 958B, sets of 9 panels 958C, and sets of 25panels 958D.

FIG. 8F shows perspective view and side views of example hollow coreutility walls 941 and concrete poured walls 942 with a 12 voltelectrical system.

The ability of sPOD to use legs as panel separators enables floors wallsand ceiling to have continuous utility channels so that utility lines(electrical communication, hot and cold water, chilling equipment areall organized and repairable separate from the physical wall andstructure—and waffle type concrete foundations floors walls and roofswhere the sPOD unit is filled with concrete in order to afford veryrobust and insulated out side in side or both sides and be connected toa poured column or pedestal foundation in a continuous fashion.

FIG. 8G is a side view of a 12 volt electrical system where the positive948 and negative 949 wiring is embedded with the criss cross crevices ofthe stressed skin panel where the struts are located but not arereplaced with 12 volt wiring with access to appliances using a plug thatconnects the two wires.

sPOD Infrastructure

In some embodiments, infrastructure is comprised of variations in theuse of frames and stresses skin elements in a similar manner as thesuper structure above but now provided for infrastructure

FIG. 9A shows top perspective views of example porous paving and bankstabilization, uses protective leg frames and protective panel frames1010, 1012, 1014, 1015, 1016, and 1017 as gravel or grass confinementsand the same as tiered steps 1018 or angled surfaces depending onsteepness of back. All frames are inter-locked or pierced into groundusing the hinge holes and pin system.

FIG. 9B shows side perspective views of an example living wall 1022 andliving roof 1021, which are similar applications to paving and bankstability uses using same interlocking and anchoring systems but oncompletely horizontal or vertical surfaces. Other support means may benecessary for these frames to function and depending on size of plantsand their roots. Varying root depths are accommodated using the verticaland horizontal capacity of both small and large frames to be attached toeach other using the hinge type assembly process. In the case of greenroofs, this enables both intensive type and extensive type green roofsystem to be installed.

FIG. 9C shows top perspective views of example Community IntegratedDistrict Utility Spines (CIDUS) 1030 and 1031. This open trellis typespine protects people from the sun and wind while also providingprotection. A mounting system is provided for a variety of utilitiesincluding communications and electricity above with the utility channelsprovided by the sPOD system and water and sewage below beside or beneatha raised sPOD side walk. In one example of dimensions of the POD unit,the width of the spine can be 4 or 8 feet. The columns for holding upthe trellis may use one of two procedures a) the stacked and pinconnected hollow leg cowlings connected into a large 4 ft×4 ft frame;and b) all poured together with appropriate concrete mix. The toptrellis connection uses the same pin connections but into larger framesfilled with the leg frames and braced by the longer struts. Other supplyutilities verses the flow utility components described above can also beaccommodated including solar PV, wind towers using the same sPOD moduleand housings for gasification to electricity stations.

FIG. 9D shows top perspective views of example green machines. Invarious examples, these green machines comprise a series of carefullydesigned and engineered volumes that enable biologically based processesto do work for humans in the sense of the rapid production of food,plant based waste water treatment, the treatment and storage of water,waste water treatment using plants that become food for chickens whoseexcrement becomes the direct food for fish. The following is adescription of these example green machines;

A first flush and cistern water tank 1041 connects the washing apparatusthat separated initial rain from the constant rain, thus letting theroof clean itself before the good water enters the cistern tank In thisexample, both the first flush module and the cistern are constructedsolely of the sPOD components.

A waste water wetland 1042 comprises a trough using the sPOD panel andframe to hold a gravel infill that function as the growing medium forscirpus type reed plants to treat the water. the system is comprised ofa settling chamber similar to a sceptic tank before the water enters thetrough.

An organic waste to vegetables and fish green machine 1043 uses twobiological processes. Soldier flies break down the organic waste in avessel that let the flies breed larvae which find there way up a ledgeand drop into the fish pond. This fish pond, in turn, has a circulatingpump that takes the fish waste water and places it within a hydroponicvegetable bed that both uses the fish waste as fertilizer and lets thatnow treated water back into the fish tank thus creating a symbioticprocess between the plants, fish fish and human need for protein andfiber while ridding the kitchen form organic waste.

A waste water to poultry and fish system 1044 uses waste water to feedpoultry using the food from the plants in a waste water wetland. Thesystem comprises two circular shallow tanks put together like a donut.The center tank and the outer tank create a trough that is planted likea waste water wetland with the same gravel growing medium and plantsthat poultry like but whose roots are protected so that only the topyoung leaves are used as food that pokes through a wire mesh. Thechickens then go up to their perching and egg laying area that issituated above the center pond. The defecation from the chickens fallsinto fish pond, and the fish use it as food since chicken dung is mostlyunder processed and can be used as fish food.

A wind generator tower 1045 is constructed from sPOD panels and frames.The structure can be held down with water as a cistern at the bottom ifthe wind system is pumping water, as a housing for a pressure tank ifthe wind system is a compressor, or as a battery storage area if it is awind electric system.

Multifunctional support pedestals 1046 are provided in order to raisebuildings with columns that are robust and will not be swept way withthe flood. The sPOD system enables a robust vertical 8 foot tall by 4×4foot base to be constructed that serves this purpose while at the sametime holding key green utility type components within. These componentsinclude but are not limited to protected regulating and chargingequipment with batteries, spiral stairs, waste water pretreatment beforeentering wetlands, garden tool storage, auxiliary power supply.

Green Manufacturing

FIG. 10 shows an example manufacturing process for carbonized foam.

The foam core material may be manufactured as carbonized foam throughwhat is referred to as a gasifier. Unlike pyrolysis that uses externalfuel to create the the necessary pressure and temperature, gasificationis a self firing system using the fumes that result from baking anorganic substance in the absence of oxygen as the fuel to run the systemitself and to fuel items like internal combustion engines. The resultingfuel is carbon monoxide and hydrogen both being partially cycled backinto the system as new material enters the combustion area through aseries of air locks. The heat generated is used at step 10 to prebake apremixed batter that has been mixed in a process similar to making cakeor bread dough and then placed into a mold. The substance possesses acertain lightness depending on yeast and rising time, and a shape suchas an sPOD foamed core panel or foamed core feet.

A high temperature capable mold with ingredients intact enters thegasification chamber at step 12. Once gasified, the material exits thechamber and is then extracted from the mold as the carbonized foam coreproduct. The usual charred material usually referred to as charcoal orbiochar now becomes a more valuable “ waste” product than before.

One uniqueness of the SPOD system is in the recognition that theresulting charred material is not only light weight and insulating,strong and fire proof but can retain the shape of the original inputmolded material albeit slightly reduced in size due to shrinkage. Thisphenomenon therefore produces a useful object. Applicant expects thatthis shape and shrinking can be controlled. The bubbles within the cakeor bread can also be controlled by the amount of yeast and the doughtype and consistency and the length of the moldering time for the yeastto rise. The importance of using the gasifier also enhances otherprocesses such as use of the waste heat for baking the bread or the fuelto operate other manufacturing processes such as running a generatorthat operates machinery, molding 3D printing, lights etc.

One goal is to have a self contained off-the-shelf manufacturing processthat is inclusive of the troughs for growing of the plants that producethe flour to make the “bread” and to incubate and refrigerate the yeast.The fact that this facility is core to how a neighborhood operates andbecomes to varying degrees self contained processes and become one ofthe processes within CIDUS (the community integrated district utilitysystem) As discussed above, a next layer of integration would includesuch processes as using part or all of the waste water generated bypeople or animals to feed the flour/fiber producing crops that feed thebasic materials for the manufacturing of components.

Material Options

Bio-based material use is in keeping with global protocols for reductionof petroleum plastics and thus the reduction of fossil fuel use.Bio-based options include but are not limited to agricultural-based(castor seed, sugar cane, mushroom, flours from wheat, rye, soy—to namea few), and sea based materials (including fishing shell extracts,algae, sea weed to name a few). It also recognizes forestry products(resins, tree based foaming agents, foams, fibers,) and reed-basedmaterials such as kenaf, bamboo, typha, and carrizo, hemp and bamboo.All these have been proven either scientifically and/ or commercially byothers to be viable options for some if not all the aspects of the sPODfamily of requirements to meet or exceed structural, manufacturing andregional economic development goals. When these materials singularly orin combination satisfy structural, environmental, human use andmanufacturing criteria for health and safety any are considered viable.

Symbol Embedded Multipurpose Communication Fork Lift Sensor andCommunication System

FIG. 11 is a side perspective view of an sPOD branding symbol 1100embossed and sealed within each part of the sPOD system. The brandingsymbol is functional in that it identifies that seed or component in thepod and enables the user to connect to a a crowd/image based trainingsystem like Image Net to learn the possible uses of that seed componentboth in super structure and infrastructure terms. The crowd sourcedlearning and exchange also enable the system to receive feedback andcreates the basis for system improvement over time. The symbol also hasthree other functions 1) a location device and 2) an inventory organizer3) a sensor for the fork lift operator to know when the forks are in theright position so as to not destroy the pallet.

What is claimed is:
 1. A modified shipping pallet comprising a shippingpallet comprising a top surface, a bottom surface, a detachablerectangular hinged pallet frame comprising four pallet frame segments,each segment forming a side of the pallet frame and configured to beattached to a side of the shipping pallet, each pallet frame segmentcomprising a top surface, a first end portion, and a second end portion;and a plurality of hinge connector blocks including a corner hingeconnector block positioned in proximity to each corner of the palletframe, and and at least one hinge connector block positioned between thefirst end portion and the second end portion of each pallet framesegment, such that each connector block includes upwardly-oriented,downwardly-oriented, and outwardly-oriented hinge sleeves.
 2. The palletof claim 1 further comprising a first stressed skin panel configured toattach to the or bottom top surface of the pallet.
 3. The pallet ofclaim 2 wherein the first stressed skin panel has an open middle solidtop surface.
 4. The pallet of claim 1 further comprising a plurality ofhinged leg frames.
 5. The pallet of claim 1 further comprising a strutgrid.
 6. The pallet of claim 1 wherein the pallet frame furthercomprises a storage compartment in each of the frame segments.
 7. A kitfor modifying a shipping pallet, the kit comprising a set of fourtubular frame elements, each frame element comprising . . . a topsurface, a first end portion, a second end portion; a plurality of hingeconnector blocks, each of the plurality of hinge connector blockscomprising upwardly-oriented, downwardly-oriented, andoutwardly-oriented hinge sleeves; a plurality of hinge pins; and aplurality of leg frames.
 8. The kit of claim 7 wherein the plurality ofhinge connector blocks, the plurality of hinge pins, and the pluralityof leg frames are shipped in the tubular frame elements.
 9. The kit ofclaim 7 further comprising a stressed skin.
 10. The kit of claim 7further comprising a plurality of strut rods.
 11. The kit of claim 7further comprising a plurality of retrofit brackets.
 12. The kit ofclaim 7 wherein the tubular frame elements are provided in bio-basedmaterials.
 13. The kit of claim 12 wherein the bio-based materialfurther comprises agricultural-based materials selected from the groupconsisting of castor seed, sugar cane, mushroom, flours from wheat, rye,or soy; or sea-based materials selected from the group consisting offishing shell extracts, algae, or sea weed; or forestry productsselected from the group consisting of resins, tree based foaming agents,foams, fibers, and reed-based materials including kenaf, bamboo, typha,and carrizo, hemp and bamboo.
 14. The kit of claim 7 wherein thebio-based material further comprises a carbonized foam.
 15. The kit ofclaim 7 further comprising an sPOD branding symbol comprising a locationelement, and inventory organizer, and a position sensor.
 16. A methodfor converting a plurality of shipping pallets to structural panels andconfiguring the structural components, the method comprising providing aplurality of shipping pallets, each pallet comprising a top surface, abottom surface, and four side surfaces; providing a plurality of tubularpallet frame elements, each frame element having a first end and asecond end, and a plurality of hinge connector blocks, each hingeconnector block having at least one of an upwardly-oriented,downwardly-oriented, and outwardly-oriented hinge pin sleeve; creating aplurality of structural panels by attaching hinge connector blocks inproximity to the first end and second end of each frame element, andattaching a frame element to each side of each of the plurality ofshipping pallets; connecting a first structural panel to a secondstructure panel by attaching a frame element of the first structuralpanel to the frame of the second structural panel by attaching a side ofthe first structural panel frame to a side of the second structuralpanel by nesting adjacent hinge connector block pin sleeves, andinserting a hinge pin in the nested pin sleeves; orienting the first andstructural panels, if necessary, by pivoting one of the structuralpanels along the connected side; and adding structural panels to theconnected first structural panel or the second structure panel bycreating additional structural panels by attaching frames to shippingpallets, attaching one or more of the additional structural panels toone or more sides of the first structural panel or the second structurepanel, and pivoting panels as necessary to achieve a desiredconfiguration.
 17. The method of claim 16 further comprising assemblingthe structural panels to a fold out structure.
 18. The method of claim16 wherein assembling the structural panels to provide a shelter. 19.The method of claim 16 further comprising enlarging the shelter byadding structural panels.
 20. The method of claim 16 further comprisingreconfiguring the structural panels.